3D printing of optimized composites with variable fiber volume fraction and stiffness using continuous fiber

Sugiyama, Kentaro; Matsuzaki, Ryosuke; Malakhov, Andrei V.; Полилов, А. Н.; Ueda, Masahiro; Todoroki, Akira; Hirano, Yoshiyasu

doi:10.1016/j.compscitech.2019.107905

Cited by 157 publications

(50 citation statements)

References 52 publications

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“…As the fibre is always aligned with the printing direction in CFRC, it is possible to control the fibre orientation. Due to the tension exerted by the reinforcing fibre, nozzle clogging can be eliminated during printing [ 164 ]. Carbon, glass and Kevlar (aramid) are majorly used in CFRC due to their better functionalities, which are beneficial in high performance applications [ 165 ].…”

Section: Fibre-reinforced Composite Printingmentioning

confidence: 99%

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

2020

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Fused deposition modelling (FDM) is one of the fastest-growing additive manufacturing methods used in printing fibre-reinforced composites (FRC). The performances of the resulting printed parts are limited compared to those by other manufacturing methods due to their inherent defects. Hence, the effort to develop treatment methods to overcome these drawbacks has accelerated during the past few years. The main focus of this study is to review the impact of those defects on the mechanical performance of FRC and therefore to discuss the available treatment methods to eliminate or minimize them in order to enhance the functional properties of the printed parts. As FRC is a combination of polymer matrix material and continuous or short reinforcing fibres, this review will thoroughly discuss both thermoplastic polymers and FRCs printed via FDM technology, including the effect of printing parameters such as layer thickness, infill pattern, raster angle and fibre orientation. The most common defects on printed parts, in particular, the void formation, surface roughness and poor bonding between fibre and matrix, are explored. An inclusive discussion on the effectiveness of chemical, laser, heat and ultrasound treatments to minimize these drawbacks is provided by this review.

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Section: Fibre-reinforced Composite Printingmentioning

confidence: 99%

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

2020

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“…In the case of continuous fibre composites, the polymer serves to transfer off-axis loads between fibres, such as shear forces. This protects the fibres, as high modulus reinforcement such as carbon and glass fibre exhibit poor mechanical properties under shear loading [ 39 ]. Continuous fibre-reinforced polymers are currently one of the largest areas of focus in 3D printing research [ 40 ]; this is due to their potential to match or exceed the mechanical performance of conventional composites.…”

Section: 3d Printing Of Continuous Fibre-reinforced Compositementioning

confidence: 99%

3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

2020

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Three-dimensional (3D) printing has been successfully applied for the fabrication of polymer components ranging from prototypes to final products. An issue, however, is that the resulting 3D printed parts exhibit inferior mechanical performance to parts fabricated using conventional polymer processing technologies, such as compression moulding. The addition of fibres and other materials into the polymer matrix to form a composite can yield a significant enhancement in the structural strength of printed polymer parts. This review focuses on the enhanced mechanical performance obtained through the printing of fibre-reinforced polymer composites, using the fused filament fabrication (FFF) 3D printing technique. The uses of both short and continuous fibre-reinforced polymer composites are reviewed. Finally, examples of some applications of FFF printed polymer composites using robotic processes are highlighted.

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“…8,13,[16][17][18][19] Flexibility of 3D printing allows to direct the fiber in the desired direction to optimize the mechanical properties of interest. 20,21 Sanei et al 21 printed continuous carbon fiber around the periphery of open hole specimen to mitigate the effect of stress concentration. They observed that failure progression into the hole was blocked by the concentric fibers around the open hole.…”

Section: Introductionmentioning

confidence: 99%

Evaluating the effect of variable fiber content on mechanical properties of additively manufactured continuous carbon fiber composites

Hetrick

Sanei

Bakis

et al. 2020

Journal of Reinforced Plastics and Composites

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Fiber volume fraction is a driving factor in mechanical properties of composites. Micromechanical models are typically used to predict the effective properties of composites with different fiber volume fractions. Since the microstructure of 3D-printed composites is intrinsically different than conventional composites, such predictions need to be evaluated for 3D-printed composites. This investigation evaluates the ability of the Voigt, Reuss, and Halpin–Tsai models to capture the dependence of modulus and strength of 3D-printed composites on varying fiber volume fraction. Tensile coupons were printed with continuous carbon fiber-reinforced Onyx matrix using a Markforged Mark Two printer. Specimens were printed at five different volume fractions with unidirectional fibers oriented at either [Formula: see text] to obtain longitudinal, shear, and transverse properties, respectively. It is shown that the Voigt model provides an excellent fit for the longitudinal tensile strength and a reasonable fit for the longitudinal modulus with varied fiber content. For the transverse direction, while the Reuss model fails to capture the transverse modulus trend, the Halpin–Tsai model provides a reasonable fit as it incorporates more experimental parameters. Like conventional composites, addition of fibers degrades the transverse strength, and the transverse strength decreases with increasing fiber volume fraction. The shear modulus variation with fiber content could not be fitted reasonably with either Halpin–Tsai model or Reuss model.

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3D printing of optimized composites with variable fiber volume fraction and stiffness using continuous fiber

Cited by 157 publications

References 52 publications

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

FDM-Based 3D Printing of Polymer and Associated Composite: A Review on Mechanical Properties, Defects and Treatments

3D Printing of Fibre-Reinforced Thermoplastic Composites Using Fused Filament Fabrication—A Review

Evaluating the effect of variable fiber content on mechanical properties of additively manufactured continuous carbon fiber composites

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